Gema MagicCompact BA04 Page 1 Operating Instructions And Spare Parts List Download

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Translation of the original operating instructions

Operating instructions and spare parts list

Powder coating booth

MagicCompact BA04

Summary of Contents for MagicCompact BA04

Page 1: ...En Translation of the original operating instructions Operating instructions and spare parts list Powder coating booth MagicCompact BA04 ...

Page 2: ...names are trademarks or registered trademarks of their respective holders Reference is made in this manual to different trademarks or registered trademarks Such references do not mean that the manufacturers con cerned approve of or are bound in any form by this manual We have en deavored to retain the preferred spelling of the trademarks and registered trademarks of the copyright holders To the be...

Page 3: ...on 11 Function description 11 Operational procedure 12 Powder flow 13 Booth superstructure 13 Booth basement 14 Floor blow off system 14 Powder suction 15 Exhaust air system with After Filter 16 Fire protection 16 Cleaning operation mode 16 Automatic booth cleaning 16 Powder recovery 16 Automatic powder guns 17 Cleaning the guns 18 Technical Data 19 MagicCompact BA04 powder coating booth 19 Electr...

Page 4: ...sioning storage 31 Introduction 31 Safety rules 31 Requirements on personnel carrying out the work 31 Storage conditions 31 Storage duration 31 Space requirements 31 Physical requirements 31 Hazard notes 31 Shut down 32 Decommissioning 32 Cleaning 32 Disassembly attachment of transport safety devices 32 Packing 32 Identification 32 Maintenance during storage 32 Maintenance schedule 32 Maintenance ...

Page 5: ... contents 3 Spare parts list 41 Ordering spare parts 41 MagicCompact BA04 spare parts list 42 Floor blow off system Pneumatics 43 Pressure regulator 44 Sensor Actor Box 45 Gun blow off equipment 46 Door drive unit 48 Fan control unit 50 ...

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Page 7: ...ous injury ATTENTION Improper use of the equipment could damage the machine or cause it to malfunction Possible consequences minor injuries or damage to equip ment NOTE Useful tips and other information Intended use The powder coating booth is built to the latest specification and con forms to the recognized technical safety regulations and is designed for the normal application of powder coating ...

Page 8: ...Explosion protection Protection type II 3D IP54 Product specific safety measures General information The MagicCompact BA04 powder coating booth is a constituent part of the equipment and is therefore integrated in the system s safety concept If it is to be used in a manner outside the scope of the safety concept then corresponding measures must be taken NOTE For further information see the more de...

Page 9: ... instructions Later on they also serve as a useful aid in the event of possible malfunctions or uncertainty and make many inquiries unnecessary For this reason the operating manual must always be available at the plant Should difficulties arise however your Gema service center is always ready to assist Inspection Before switching on the booth check the following points where applica ble No foreign...

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Page 11: ...al system components booth OptiCenter gun control unit gun or powder injector should be referenced to their corresponding documents DANGER Working without operating instructions Working without operating instructions or with individual pages from the operating instructions may result in damage to property and personal injury if relevant safety information is not observed Before working with the de...

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Page 13: ...unction description The principle of function is determined by the requirements placed on the booth which are The protection of the coating process from external influences com bined with keeping the area around the booth clean The powder recovery The avoidance of an explosive powder air mixture inside the booth An efficient exhaust air system is used to keep the area around the booth clean and to...

Page 14: ...is reached as soon as all external plant units such as chain conveyor OptiCenter reciprocators optionally fire protec tion optionally etc are switched on The operating functions in the OptiCenter can be released now and the coating process can begin This process is interrupted only if a ventilator motor malfunction is present Other malfunctions are indicated by an alarm or a message displayed on t...

Page 15: ...n for the coating process The rest of the non separated powder most of it is fine particles goes in to the after filter 5 The after filter separates the powder into a waste container 6 which is positioned directly under the filter elements and is very easy to empty The cleaned air then exits the filter and is fed directly back into the workshop environment Booth superstructure The booth superstruc...

Page 16: ...he floor blow off unit and the powder suction suction duct fig 2 Basement Floor blow off system fig 3 floor blow off system arrows blow off direction A blow off rail with blow nozzles is integrated lengthwise into the booth floor The blow off rail consists of various segments which can be pneu matically controlled one by one Floor blow off Suction duct ...

Page 17: ...to 5 0 bar The pressure regulator for the floor blow off system can be set to max 3 bar Powder suction fig 4 powder suction cutaway view The powder suction takes place via a lengthwise suction duct in the booth floor The powder which has been blown by the floor blow off system in the direction of the suction slot is then sucked in along the entire booth length The suction duct is gathered in a cro...

Page 18: ...osed thereby an increased air inlet speed results at the remaining openings at the booth This ensures a dust free environment around the booth during the color change procedure Automatic booth cleaning The cleaning of the booth floor takes place automatically with the combi nation of the floor blow off system and the powder suction see the chap ter on Booth Basement Powder recovery A safe and clea...

Page 19: ...the electrode rinsing air are outside of the coating booth These supply attachments are integrated into the gun enabling the guns to can be cleaned automatically by blow off nozzles The powder hose connection makes possible a perfect fixing of the pow der hose by the clamping device This is a prerequisite for the automatic rinsing of the powder transport equipment further information about au toma...

Page 20: ...y the gun blow off equipment on the coating booth By activating the cleaning function on the control unit the reciprocators and the guns move out of the booth At the same time each gun is blown off cleanly from the outside by four flat jet blow off nozzles These flat jet blow off nozzles are found on the gun slots on the outside of the booth If necessary this cleaning sequence can be repeated ...

Page 21: ... max 10 bar Air entry speed 0 7 m sec Rinsing air in filter housing max 18 Nm h Water vapor content of compressed air max 1 3 g m Oil content of compressed air max 0 1 mg kg Dimensions MagicCompact BA04 Booth length max 4 5 m in the interi or Booth width 1 6 1 8 2 0 m Booth basement height 0 6 m Weight Booth inside length 3000 mm Booth inside width 1800 mm Superstructure height approx 3250 mm appr...

Page 22: ...ed while the unit was in operation measurements were taken at the most frequent operator positions and at a height of 1 7 m from the ground The specified value is applicable only for this product itself and does not take into account external noise sources or cleaning impulses The sound pressure level may vary depending on the product configura tion and space constraints ...

Page 23: ... junctions The connecting cables between control unit and guns must be laid out in such a way that they cannot be damaged during operation Observe the safety regulations Grounding The ground connection of the booth should be checked each time the equipment is put into operation The grounding connection is customer specific and fitted on the booth basement the cyclone separator and the filter housi...

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Page 25: ... After Filter Switch on the booth 1 Open the compressed air supply and set the input pressure for the After Filter 2 Turn on the main switch the main switch is located on the control cabinet 3 Turn the key switch the control unit is activated the operating unit is activated and the key switch returns to its starting position 4 Start the system the main menu appears on the operating unit 5 Activate...

Page 26: ...e input is entered directly on the operating unit of the plant con trol see also the operating manual of the plant control unit Color change and cleaning The color change can begin when the last workpieces have left the booth In automatic operation mode the coating is stopped automatically Following a step by step description of the color change procedure from bright to dark or vice versa is given...

Page 27: ...low off the recovery system if necessary wipe off the cyclone cone Blow off the inside of the monocyclone with the air lance 9 Prepare the equipment for coating Make the recovery system ready for operation Put the OptiCenter into coating operation Put the booth into coating operation switch on the plant move the XT axis into coating position start the correct reciprocators program 10 Check the gun...

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Page 29: ...ndow of the filter housing above the door If powder deposits are present this is an indication of de fect filter elements replace the filter elements see After Filter oper ating instructions Check all oil separators and if necessary empty if oil is present the compressed air preparation must be checked Biannually Disconnect the measuring lines of the pressure gauges on the ma nometer and blow it o...

Page 30: ...h or if damaged replace it Further information see the corresponding operating manual Maintenance of the After Filter pressure gauges filter and fan The following check should be carried out regularly Notice the pressure on the pressure gauges and compare with the original pressure values which were set by the Gema service engi neer at the first start up If errors arise see the troubleshooting gui...

Page 31: ...d on 2 Turn the key switch the control unit is activated the operating unit is activated and the key switch returns to its starting position Control units and all interlocked equipment should not be able to be switched on 3 Start the system the main menu appears on the operating unit 4 The operation of the OptiCenter is described in the corresponding user manual 5 Switch on the gun control units i...

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Page 33: ...re are any uncertainties please contact Gema Storage conditions Storage duration If the physical conditions are maintained the unit can be stored indefinite ly Space requirements The space requirements correspond to the size of the booth parts plus the packaging The load bearing capacity of the floor should be at least 500 kg m There are no special requirements concerning distance to neighboring e...

Page 34: ...safety de vices use supplied transport utilities again Packing A suitably stable pallet big enough must be used To prevent damage to the components collisions with other parts must be prevented It is definitely not recommended to stack the individual parts Should this nonetheless be planned the packaging must be made robust enough to protect the booth parts against additional forces Identification...

Page 35: ...ge 33 Return to service Commissioning following storage Before mounting the booth make sure that all plastic components such as panels have been acclimatized at a room temperature of at least 15 C for at least 24 hours ATTENTION Avoid stress cracks ...

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Page 37: ...ed when moving parts that are sometimes bulky and heavy Components being disassembled must be adequately secured before they are detached Requirements on personnel carrying out the work Use only technical personnel who are trained in operating the respective equipment e g a crane If there are any uncertainties please contact Gema Packing material Not necessary for the internal transport For extern...

Page 38: ... Loading transferring the load unloading Exercise caution at temperatures below 5 to 15 C ATTENTION Avoid stress in the plastic material The plastic booth must not be transported at temperatures below 15 C In summer the air temperature during transport should not exceed 60 C ATTENTION Avoid heat accumulations and storage in sunlight Suitable lifting equipment is to be used for all procedures ...

Page 39: ...ounds at the same time with every message malfunc tion or emergency stop Problem fixing Problem error malfunction Procedures remedy Alarm has been released Message too little powder Display flashes in the OptiCenter Powder shortage in the powder container Acknowledge error fill in fresh powder Switch off the alarm fill in fresh powder Alarm has been released Message EMERGENCY STOP protective switc...

Page 40: ...x haust air because too little or no air resistance Filter housing door is open Sieve machine not fitted tightly on the cyclone separator Waste container not fitted tightly see also the troubleshooting section in the After Filter manual Alarm has been released Message Fan low pressure Maximum pressure in the filter housing exceeded correspond ing pressure gauge responding Pressure too high insuffi...

Page 41: ...yclone casing for holes caused by wear Check the pretension force of the closings Sieve clogged up Check the powder for dampness Check if too much powder was fed through the cyclone e g dur ing the booth cleaning Automatic floor blow off system not OK Check the compressed air supply Pressure reducing valve defec tive or adjusted incorrectly Solenoid valve defective coil cable or missing signal Set...

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Page 43: ...6 1 piece Clamp Ø 18 15 mm When ordering cable or hose material the required length must also be given The spare part numbers of this bulk stock is always marked with an The wearing parts are always marked with a marked All dimensions of plastic hoses are specified with the external and internal diameter Example Ø 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d ATTENTION Only original Ge...

Page 44: ...s see separate spare parts list 2 Pressure regulator see separate spare parts list 3 Sensor Actor Box see separate spare parts list 4 Gun blow off equipment see separate spare parts list 5 Door drive unit see separate spare parts list 6 Fan control unit see separate spare parts list fig 7 Spare parts 1 4 2 4 6 5 3 ...

Page 45: ... blow off system Pneumatics 3 Solenoid valve 1 2 NW 13 5 24 VDC 1005 120 4 Valve coil for pos 3 24 VDC 1005 119 7 Valve cable 3 pins M12 for pos 4 1008 244 15 Hose Ø 12 10 mm 100 382 Please indicate length fig 8 Floor blow off system Pneumatics 4 3 15 7 ...

Page 46: ...10 17 44 Spare parts list MagicCompact BA04 Pressure regulator 1 Pressure regulator 0 8 bar 1 1008 185 2 Pressure gage 0 10 bar 1 8 243 620 3 Adapter nipple 1 8 1 4 231 932 fig 9 Pressure regulator 3 2 1 ...

Page 47: ...mpact BA04 Spare parts list 45 Sensor Actor Box 1 Sensor Actor Box M12 8P 1008 242 2 Y distributor threefold M12 1008 246 3 Plug screw M12 1006 905 4 Sensor actuator cable 30 m 1008 243 fig 10 Sensor Actor Box 2 3 1 4 ...

Page 48: ...3 094 4 Allen grub screw M6x16 mm 214 850 5 Nozzle holder type 2 complete 1013 091 6 Compressed air hose Ø 16 25 mm black 105 155 7 Hose clamp Ø 17 25 mm 223 085 8 Hose connector 1013 093 9 Intermediate Pipe 1013 732 10 Tube Ø 20 17 mm 1013 098 11 Solenoid valve 1005 592 12 Valve coil 24 VDC for pos 11 1005 119 13 Valve cable 3 pins M12 for pos 12 1008 244 14 Grounding cable complete 1006 077 Plea...

Page 49: ...V 10 17 MagicCompact BA04 Spare parts list 47 Gun blow off equipment fig 11 Gun blow off equipment ...

Page 50: ...30 Double nipple 1 8 1 4 242 209 32 Y connection fitting 1 8 Ø 8 mm 253 936 33 Adjusting elbow Ø 8 8 mm 238 287 35 Elbow joint 1 4 Ø 8 mm 254 029 39 Plastic tube Ø 8 6 mm black antistatic 103 756 40 Rubber buffer Ø 40x28 mm M8 248 592 41 Hexagon screw M5x10 mm 205 699 43 Hexagon shakeproof screw M6x12 mm 244 406 45 Hexagon shakeproof screw M8x20 mm 244 422 46 Cylinder Allen screw M4x20 mm 216 291 ...

Page 51: ...V 10 17 MagicCompact BA04 Spare parts list 49 Door drive unit A 41 56 57 41 56 4 47 1 2 7 43 18 8 21 6 58 3 33 39 32 24 35 59 45 5 A 27 30 23 48 51 56 17 16 15 13 46 50 55 40 fig 12 Door drive unit ...

Page 52: ...ion M25 1 9 18 mm 1008 283 10 T piece 6 mm 1 8 6 mm complete 1006 645 11 Elbow joint 1 8 Ø 6 mm complete 242 195 12 Connection sleeve 1 8 Ø 6 mm complete 201 324 13 Screw in nipple 1 8 Ø 8 mm 261 653 14 Switch 1 25 11 0 kPa 243 752 15 Pressure gauge 0 8 0 kPa differential pressure 251 844 16 Pressure gauge 0 5 0 kPa differential pressure 243 779 20 Main switch see corresponding wiring diagram Wear...

Page 53: ...V 10 17 MagicCompact BA04 Spare parts list 51 Fan control unit fig 13 Fan control unit ...

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